Covered trim panel and method of manufacturing same



P. R. ZINSER Nov. 5, 1935.

COVERED TRIM PANEL AND METHOQOF MANUFACTURING SAME Filed Sept. 25. 1953 I INVENTOR. Paul F. Z1716 er ATTORNEYS.

Patented Nov. 1935' PATENT OFFICE COVERED 'rnm PANEL AND METHOD MANUFACTURING sum Paul a. Zinser, Detroit, Mich, ass'ignor to Woodall Industries Incorporated, Detroit, Mich, a corporation of Application September 25, 1933, Serial No. 690,959

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My invention relates to covered panels and particularly to automobile interior trim panels wherein the foundation of the panel is formed of suitable composition fibrous material and to an improved method of their manufacture. A suit- I able foundation board is one possessing thermoplastic characteristics whereby it may be stamped under-heat and pressure to assume and retain an embossed configuration. One surface, which surface is to be the exposed face of the finished panel, is covered with upholstery fabric or other suitable trim material.

An object is to provide such a panel wherein a foundation board is given an embossed design or bead and the covering material is so secured thereto that it is stretched taut over the embossment ,or bead formed in the foundation board and is so secured to the board along the base of the embossment or bead or outline that such embossment will stand out sharp and clear against the background of the covered panel and the fabric will be held securely against accidental detachment along the base of the embossmentor bead.

It has heretofore been found that while finishing material such as any suitable trim fabric may,

be easily adhesively secured to the flat face of a panel board that it is difl'icult to securely fasten the same over an embossed surface andstretch it taut over the risers and embcssments and then fasten .it down securely along the base of such risers. When the material'is stretched overthe embossed surface there is a tendency for it to pull loose and become detached along the base' of the embossment. The stretching of the fabric taut places a strain thereon along the base of the embossment and it tends to loosen along such line. Loosening1 of the fabric along this line not only destroys t e appearance of the design but forms a line from which such loosening continues and increases to the ultimate impairment of the panel.

In accomplishing the objectof my invention I propose to form a line of small spaced apart cavi-- ties along the base of the embossment or bead and to press the covering material into these cavities in such a manner that it is interlocked therev in so that it will be interlocked at intervals along the base of the embossment over which it is stretched andwill be securely held within the interior of the foundation board against accidental detachment from the board.

It has also been foundthat this mechanical interlocking of the material at intervals along j handled as to constitute a decorative treatment'of the board. I therefore propose to interlock the material at such intervals and in such a manner that, the cavities into which it is depressed and interlocked will have the appearance of stitch 5 apertures formed at the .end of the individual stitches ofa line of stitching; Through adopting this treatment the appearance of the covered panel is actually enhanced by the operation.

Other objects and advantages will more fully 10 appear from the following description, appended claims, and accompanying drawing, wherein:

Figure 1 is an'elevation of a fragment of the interior of an automobile door showing a panel structure embodying my invention secured 15 thereto,

Figure 2 is an enlarged fragmentary elevation of a portion of the panel shown in Figure 1,

Figure 3 illustrates a cross section through a panel board with trim fabricsecured thereto prior 20 to being treated according to the improved process embodying my invention, and I Figures 4 and 5 represent cross sections taken on lines 4-4 and M .of Figure 2, respectively.

In carrying out my invention I employ a suitable 35 foundation board to serve as the foundation of 9. complete covered panel. This foundation board is formed of any suitable fibrous composition mav terial possessing the desired characteristics. I prefer to employ a fibrous composition board 5 which possesses thermoplastic characteristics due to the presence of a thermoplastic binder and what is commercially known as KB board has been satisfactorily employed by me.

In the figures of the drawing this foundation :5 board is indicated as Ill and is-provided on one A surface with a suitable covering material such as fabric trim material indicated as I2. This trim material may be of any suitable woven or felted fabric or of any other character, such as 40 I artificial leather or the like. In carrying out my invention the trim material is adhesivel'y secured to one surface of the foundation board by a suitable adhesive as shown in'Figure 3.

It has heretofore been proposed to emboss the normal plane of the board or withindepressions which may be formed therein as in head work due tov the stretching of the fabric and the tendency of the adhesive to loosen at these points of strain. It has heretofore been proposed to stitch the fabric along these points of strain but such stitching possesses I disadvantages. The stitching weakens the interior structure of the panel board so that when the complete board is subjected to bending or other strain it has been found that there is a tendency to break along the line of stitching and such breakage in covered stitched panels always curl along the line of stitching. Furthermore. the stitching produces a series of perforations in the board which serve as entrance points for moisture to seep'in to produce warping or other deformationswhich result from the entrance of moisture into a cellulose fibrous product unless the waterproofing characteristics of the product are such as to prevent such seepage.

I have found that the covering material may be securely held in place by so stamping the covered panel board as to produce a series of cavities or depressions ll along the outline of the embossment into which the covering material is driven so as to be interlocked and securely held therein. These cavities are illustrated in Figures 4 and 5 where it will be noted that the covering material is driven into the cavities in the form of a fold and these cavities are spaced apart along the line of the bead which is indicated'as l6. It is obvious that the cavities might be formed along the outline of any embossed design as well as a bead. Bead work is common practice and my i1- lustration in connection with such a form is merely to exemplify the carrying-out of my inventive idea. It will be noted that'the forming of these cavities is carried out in the die in such a fashion that the board is not reduced in thickness at such point, a protuberance 18 being formed on the rear face of the panel board opposite each cavity representing a corresponding def ormation of the structure.

To overcome any objection to this type of stamping the operation is soparried out as to simulate the appearance of stitching so that the treatment of the panel presents an appearance which is typical of a stitched panel without the disadvantages which attend the stitching of the fibrous thermoplastic material, covering material adhesively secured over one surface thereof, said panel board providedwith an embossed design over which the covering material is stretched taut, said board provided along the base of said design with a plurality of small spaced apart cavities, said covering material being depressed and packed into said cavities and securely locked therein. l

2. A trim panel comprising a panel board of composition fibrous material, flexible 'covering' material adhesively secured over one surface of 3. A trim panel comprising a panel board of fibrous composition material, trim fabric material adhesively secured over one surfacethereof,

said panel board provided with a bead embossed therein, and having a groove debossed in the board along the base of the bead, said trim fabric materialbeing adhesively secured to the board along the base of the bead through being forced into small cavities formed in the board in the bottom of the groove at spaced apart intervals.

4. That method of fabricating a trim panel and covering the same with fabric trim material comprising adhesively securing trim fabric material over oneface of fibrous composition thermoplastic foundation board, stamping said covered panel board under heat and pressure producing an embossment therein. and providing along the base of said embossment small spaced apart cavities into which the trim fabric is drivenand interlocked to hold the same securely along the base of the embossment.

5.'That method of fabricating a trim panel and covering the same with fabric trim mate- 30 rial comprising adhesively securing trim fabric material over one face of the fibrous composition thermoplastic foundation board, stamping said covered panel board under heat and pressure producing the bead therein and pressing the trim fabric material into the structure of the foundation board at spaced apart intervals along the base of the bead to interlock the same into the bottom at such points.

.6. A trim panel comprising a panel board of fibrous composition material, trim fabric material adhesively secured over one surface thereof, said panel board provided with a bead embossed therein and having grooves debossed in the board along each side of the bead, the base of said grooves being shaped with a plurality of small spaced apart cavities into which the trim fabric is driven into in folded formation to stretch the same in taut condition over the head.

'7. A trim panel comprising a panel board of fibrous thermoplastic material, fabric material covering one face of said panel, said panel board being shaped at spaced apart 'intervals along the base ofsaicl design to form a plurality of small cavities in one face of the board each having a corresponding protuberance on the other face of the panel, said fabric material being driven deep into said cavities and interlocked with the thermoplastic board to stretch the fabric 60 

